Rear Differential Reassembly
Rear Differential Reassembly
Special Tools Required
- Oil seal driver 07JAD-PL90100
- Holder handle 07JAB-001020A
- Attachment, 40 x 50 mm I.D. 07LAD-PW50601
- Attachment, 45 x 55 mm I.D. 07MAD-PR90100
- Attachment, 78 x 80 mm 07NAD-PX40100
- Companion flange holder 07RAB-TB4010B
- Universal holder 07725-0030000
- Driver, 40 mm I.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300
- Driver 07749-0010000
1. Apply Hondalock 1 (P/N 08713-0001) to the surface of ring gear and the ten mounting bolts.
2. Install ring gear, then tighten the ten mounting bolts in a crisscross pattern in several steps.
3. Install the tapered roller bearing using the 40 x 50 mm I.D. attachment (A) and a press as shown.
4. Install the standard thrust washer 3.47 mm (0.1366 in.) (A) onto drive pinion gear (B). Then install the tapered roller bearing (C) using the old pinion spacer (D), the 40 mm I.D. driver (E), and 30 mm I.D. attachment (F) as shown.
5. Install the bearing outer races (A) into the differential carrier using the 45 x 55 mm I.D. attachment (B), the 40 mm I.D. driver (C), the 78 x 80 mm attachment (D), and driver (E) as shown.
6. Apply the recommended fluid to the tapered roller bearing (A), then install drive pinion gear (B) and new pinion spacer (C) into the differential carrier (D).
7. Apply the recommended fluid to the tapered roller bearing (A), then install the tapered roller bearing and the spacer (B) using the 40 mm I.D. driver (C) and the 30 mm I.D. attachment (D) while holding drive pinion gear (E).
8. Install a new oil seal using the companion flange and the 40 mm I.D. driver (A) as shown.
9. Apply molybdenum grease to the surface end of the companion flange, then install the companion flange (A), the drive pinion washer (B), and a new locknut (C).
10. Install the holder handle (A) and the companion flange holder (B) to the companion flange, then tighten the locknut to 20 N-m (2.0 kgf-m, 14 lbf-ft).
11. Rotate the drive pinion several times to ensure proper tapered roller bearing contact. Measure the drive pinion turning torque before tightening the locknut to the specified torque.
12. Tighten the locknut to 127 N-m (13.0 kgf-m, 94 lbf-ft), then remove the holder handle (A) and the companion flange holder (B).
13. Rotate the drive pinion several times to assure proper tapered roller bearing contact. Measure the drive pinion turning torque.
- If the drive pinion turning torque exceeds the standard, replace the pinion spacer.
- If the drive pinion turning torque is less than the standard, adjust by tightening the locknut a little at a time, but keep the torque within 127-284 N-m (13.0-29.0 kgf-m, 94-210 lbf-ft). If this is not possible, replace the pinion spacer.
Tp: Actual measurement of drive pinion turning torque
14. Install the Torsen LSD assembly (A), the bearing outer races (B), and the adjustment screws (C) onto the differential carrier.
NOTE:
- Reinstall the adjustment screws in their original position on the differential carrier.
- Align the threads of the adjustment screws and the differential carrier housing.
15. Install the bearing caps (A) while aligning both marks (B) on the threads of the adjustment screws and the bearing caps, then install the mounting bolts finger-tight.
16. Measure the backlash of the ring gear. Rear Differential Backlash Inspection
17. Tighten the bearing cap mounting bolts.
18. Thoroughly clean the ring gear teeth (A) and the drive pinion gear teeth, and paint the ring gear teeth (B) with Prussian Blue lightly and evenly.
19. Rotate the companion flange (C) three full turns forward and then backward to produce a contact pattern on the ring gear. During this operation, resistance should be applied to the ring gear.
20. Check the tooth contact pattern and adjust it if needed.
- Toe Contact: Use a thinner thrust washer to move the drive pinion gear away from the ring gear.
- Heel Contact: Use a thicker thrust washer to move the drive pinion gear toward from the ring gear.
- Flank Contact: To move the ring gear away from the drive pinion gear, tighten the adjustment screw on the drive pinion gear side, and loosen the adjustment screw on the ring gear side. Recheck backlash after adjusting the adjustment screws. If out of specification, adjust as described under Toe Contact.
- Face Contact: To move the ring gear toward the drive pinion gear, tighten the adjustment screw on the ring gear side, and loosen the adjustment screw on the drive pinion gear side. Recheck the backlash after adjusting the adjustment screws. If out of specification, adjust as described under Heel Contact.
Thrust Washer
*: Standard
21. Rotate the Torsen LSD assembly several times to ensure proper tapered roller bearing contact.
Measure the Torsen LSD assembly preload using a push/pull gauge.
- If the Torsen LSD assembly preload exceeds the standard, adjust by loosening the adjustment screws a notch at a time.
- If the Torsen LSD assembly preload is less than the standard, adjust by tightening the adjustment screws a notch at a time.
22. Install the lock plates (A).
23. Install a new oil seal using the oil seal driver (A) as shown.
24. Install the breather plate (A), the drain plug (B), and a new sealing washer (C). Install the filler plug (D) with a new sealing washer (E) finger-tight.
25. Clean the dirt and oil from the mating surfaces. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the differential case and the differential carrier. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Allow it to cure at least 30 minutes after assembly before filling the differential with the recommended fluid.
26. Install the differential case (A) with the ten mounting bolts finger-tight.
27. Tighten the ten mounting bolts in a crisscross pattern in several steps.
28. Replace both clips (A) on the output shafts. Make sure the clips are installed in the output shaft grooves (B).
29. Install the output shafts (A).
